RZ500 Restoration update

Got a customizing or restoration project? Post your progress pictures and updates here

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tacky1
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Location: Bay Area. CA.

Re: RZ500 Restoration update

#16 Post by tacky1 » Thu Apr 27, 2017 3:12 pm

If I remember correctly, There is a little ring clip on the inside, You screm the cap down tight on the outside and the bolt will stick into the unit, You can see it when you pop the top off the unit. I will check tonight, I have a few taken apart where I made the best out of them all.
1985 RZv500
1984 RZ500 Hybrid
1986 RG500 Walter Wolf
1986 RG500 Skoal Bandit
1984 RZ350
1984 RZ350 Hybrid
1981 RD350LC
1981 RD350LC Hybrid
2009 CR500AF Supermoto 250X
2007 CR500AF 250X
1988 YSR50 (2)
1989 VFR750R RC30
1984 GPZ750 Turbo

silverstrom
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Re: RZ500 Restoration update

#17 Post by silverstrom » Thu Apr 27, 2017 5:24 pm

I just went out back and looked at a set of forks that I got a few months ago. One of the plastic caps was split on the side and I was able to completely unscrew it from the anti-dive unit. The indicator (with red ring) has a lip on it and normally that lip would stop the cap from being removed. Because this cap had a split it in it easily went past the indicator lip. The cap is moulded over a bolt. That bolt threads into the anti-dive unit and pushes the piston inside. The other cap I just tried to removed is seized solid. The adjuster won't turn. I tried forcing it but I can feel the cap turning on the bolt inside. This is where the problems begin with these units. They are set and seldom adjusted again and the bolt seizes to the unit threads. You try to turn it and it then strips the inside of the cap or the cap cracks. So, in a normal situation the cap is not intended to be removable. If you heat the plastic you should be able to screw the cap past the indicator lip, and hopefully without damaging it. If you need a cap, you need to make sure it still has the bolt securely moulded inside. Otherwise, there is no way of securing the cap to the anti-dive unit. If your cap is missing you should be able to take the cap and bolt assembly from another anti-dive unit using caution, and some heat if necessary to soften the plastic. There is no need to replace the whole anti dive-dive unit. At least in a perfect world.

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Speed Freak
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Re: RZ500 Restoration update

#18 Post by Speed Freak » Fri Apr 28, 2017 6:58 am

Maybe this picture will help to describe the situation ;)

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I have also 2 forks, one fork without the knobs and one with repaired knobs, good enough to take some measurements.
Problem is also that water can go into this adjusters and will not dry for a long time inside, this is why they are often locked solid.
The piston which is pushed up by the screw is not zinc coated, so it starts to rust when there is no grease.
When removing the knobs there are 3 areas where something can happen:
1) The plastic knob will break in 2 halves when you screw it out over the step which should avoid that you can do that.
2) The bolt will turn inside the plastic
3) The inner plastic part is so brittle that it breaks into 20pieces while screwing out the knob.


I have made an improved design for them, drawings are at the workshop for prorotype manufacturing.
Depending on how the guy has time I will get it in the next week(s).
Fully sealed and it will be possible to fill them with grease to avoid rust inside the adjuster.

They should look to ~98% the same as the original parts.
My bikes:
RD500 YPVS 1GE
RD350 YPVS 31K 1985
Honda CBR 1000 RR SC57
Yamaha R1 RN04

Jarrettvp
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Re: RZ500 Restoration update

#19 Post by Jarrettvp » Mon May 08, 2017 6:11 pm

More updates - been busy with spray paint !

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Yamaha R6
Yamaha RZ500
Ducati Panigale 959

silverstrom
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Re: RZ500 Restoration update

#20 Post by silverstrom » Mon May 08, 2017 6:19 pm

Good work. The polished bolts are a nice touch.

rd84
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Re: RZ500 Restoration update

#21 Post by rd84 » Tue May 09, 2017 4:35 am

Looks good - nice to see your progress

Cheers
Paul

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Kalim
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Location: France - Nantes

Re: RZ500 Restoration update

#22 Post by Kalim » Tue May 09, 2017 7:43 am

That's shiny ! Looks good.

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jackson.40
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Re: RZ500 Restoration update

#23 Post by jackson.40 » Tue May 09, 2017 8:46 am

Keep up the good work! :cool:

Steve

Jarrettvp
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Re: RZ500 Restoration update

#24 Post by Jarrettvp » Sun May 21, 2017 5:01 am

Update from some productive work over the weekend. Still undecided as to whether to use this after market disc or get the original skimmed. Trying to keep the bike as original as possible.

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Yamaha R6
Yamaha RZ500
Ducati Panigale 959

Jarrettvp
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Re: RZ500 Restoration update

#25 Post by Jarrettvp » Wed May 24, 2017 5:35 pm

Update - we can now change gears ?

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Yamaha R6
Yamaha RZ500
Ducati Panigale 959

Jarrettvp
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Re: RZ500 Restoration update

#26 Post by Jarrettvp » Fri May 26, 2017 6:06 pm

Got my forks back from Maxton suspensions n today (just before they head out to the Isle of Man TT races). They look and feel superb. Glad I opted to not customise with modern cassettes. Stuck to the originals. Spread Freak - need that replacement "knob" now for the anti dive unit ?

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Yamaha R6
Yamaha RZ500
Ducati Panigale 959

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Kalim
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Re: RZ500 Restoration update

#27 Post by Kalim » Sat May 27, 2017 3:23 am

:smt007

Jarrettvp
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Re: RZ500 Restoration update

#28 Post by Jarrettvp » Sat Jun 24, 2017 5:45 pm

Update - started to get the exhausts on. Tackling the air filter and carbs next!

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Yamaha R6
Yamaha RZ500
Ducati Panigale 959

HWY9CA
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Re: RZ500 Restoration update

#29 Post by HWY9CA » Wed Jun 28, 2017 2:35 pm

Nice work!!!

JT
http://www.rdsonly.com/
JT
1975 RD350B
1975 RD250B -rough
1979 RD400 Race bike- in process
1985 RZ500 - flame bike
1993 TZ250 4DP2- to be restored

Jarrettvp
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Re: RZ500 Restoration update

#30 Post by Jarrettvp » Sat Jul 29, 2017 6:45 pm

Clocks went back on today. Could do with replacing the rubber seal around the top. Not sure if you can still get them?

https://www.dropbox.com/s/lmqw22nnd8udm ... .jpeg?dl=0" onclick="window.open(this.href);return false;

https://www.dropbox.com/s/t48a5aacpg2ky ... .jpeg?dl=0" onclick="window.open(this.href);return false;
Yamaha R6
Yamaha RZ500
Ducati Panigale 959

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